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Research Papers: Elastohydrodynamic Lubrication

Investigation of Patterned Textures in Ball-on-Disk Lubricated Point Contacts

[+] Author and Article Information
Wang Wenzhong

School of Mechanical Engineering,
Beijing Institute of Technology,
Beijing 100081, China
e-mail: wangwzhong@bit.edu.cn

Shen Dian, Zhang Shengguang, Zhao Ziqiang

School of Mechanical Engineering,
Beijing Institute of Technology,
Beijing 100081, China

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received March 27, 2014; final manuscript received September 9, 2014; published online October 21, 2014. Assoc. Editor: Dong Zhu.

J. Tribol 137(1), 011502 (Oct 21, 2014) (12 pages) Paper No: TRIB-14-1070; doi: 10.1115/1.4028605 History: Received March 27, 2014; Revised September 09, 2014

The numerical simulations of surface textures in point-contact lubrication are conducted based on the unified Reynolds equation model. The textures are numerically produced on one of the interacting surfaces. The lubricant rheological parameters used in the simulations are calibrated by experiments. The numerical results show good agreements with those from experiments. The friction reduction mechanism is investigated by systemically analyzing the periodic change of friction coefficient of textures. It is illustrated that the transient friction coefficient is minimal when the dent moves to the front boundary edge of the Hertzian contact zone. A local film enhancement region will be formed on the trail of the dent within the Hertzian contact region. The results suggest that a bigger local film enhancement area will offer stronger film thickness enhancement as well as a lower friction coefficient. Different pattern distributions are also studied to find the optimal distribution of patterned textures, which not only achieves a lower friction coefficient, but also offers stronger film thickness enhancement; moreover, the optimal distribution is numerically proved to be applicable for a wide range of working conditions.

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Figures

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Fig. 1

Experimental model

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Fig. 2

A disk sample with textured surface

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Fig. 3

Flow chart of research

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Fig. 4

Schematic diagram of computational domain

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Fig. 5

Cross section of microdent used in simulation along with the measured profile of dent

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Fig. 6

Comparison of friction coefficients obtained by numerical simulation and experiment at different speeds

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Fig. 7

Effect of dimensionless texture interval LX on friction coefficient

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Fig. 8

Film thickness and pressure profiles along centerline for the lowest friction coefficient

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Fig. 9

Periodic change of lubrication characteristic parameters for texture W4

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Fig. 10

Contour plots of film thickness at P1, P2, P3, and P4 moments for texture W4

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Fig. 11

Contour plot of film thickness for the dent located in Hertzian zone

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Fig. 12

Film thickness profiles at different instants and the variation of friction coefficient against time step

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Fig. 13

Profile comparison between film thickness and undeformed dent along centerline

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Fig. 14

Volume change of compressed dent with time from P3 to P4

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Fig. 15

Comparison of friction coefficient for patterned textures with different parameters: (a) Different surface shapes of single-row textures, T, P and Q. The arrow indicates the motion direction. LA, LB, and LX are all dimensionless. T: LA × LB × LX = 1 × 0.4 × 2; P: LA × LB × LX = 0.632 × 0.632 × 2; Q: LA × LB × LX = 0.4 × 1 × 2; the bottom shapes are all flat and the depths are all 1 μm. (b) Comparison of friction coefficient from different surfaces shapes. (c) Comparison of friction coefficient for different LA with constant LB. T1: LA × LB × LX = 1 × 0.4 × 2; T2: LA × LB × LX = 1.5 × 0.4 × 2; T3: LA × LB × LX = 2 × 0.4 × 2; T4: LA × LB × LX = 3 × 0.4 × 2; T5: LA × LB × LX = 5 × 0.4 × 2.

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Fig. 16

Contour plot of film thickness for T, P, Q, and T2–T5 in Fig. 15

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Fig. 17

Comparison of friction coefficient under different combinations of (LB, LX): (a) Average friction coefficient against Lx for constant LA and different LB (3/8 in. ball, 20 N, 0.1 m/s), (b) lowest friction coefficient for different (LB, Lx), (c) average friction coefficient against Lx for constant LA and different LB (3/8 in. ball, 20 N, 0.1 m/s), and (d) average friction coefficient against Lx for constant LA and different LB (1 in. ball, 20 N, 0.1 m/s)

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Fig. 18

Optimal distribution of single-row textures and Profiles of film thickness and pressure: (a) Schematic plot for optimal distribution of single-row textures and (b) film thickness and pressure profiles along center line for the optimal distribution

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Fig. 19

The change of friction coefficient with time step for LB = 0.6

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Fig. 20

Comparison of different texture patterns: (a) Average friction coefficient for different texture patterns and (b) average film thickness for different patterned textures

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